Hyster H36.00-48.00E to HR45H Four-Speed Powershift Transmission Maintenance And Repair

Description

• Model List:
  • H36.00-48.00E, H40.00-52.00XM-16CH, RS45-27CH, RS45-30CH, RS45-27IH, RS46-33CH, RS46-30IH, RS46-36CH, RS46-33IH, HR45-25, HR45-27, HR45-31, HR45-40S, HR45-36L, HR45-40LS, HR45-45LSX, HR45H

• 1. RM0634-(03-2005)-US-EN
• 1.1. Four-Speed Powershift Transmission
• 1.2. Safety Precautions Maintenance and Repair
• 1.3. General
• 1.4. Automatic Powershift Control
• 1.5. Transmission Control System
• 1.6. Transmission Control Lever
• 1.7. Mechanical Description and Operation
• 1.8. General
• 1.9. Torque Converter
• 1.10. Description
• 1.11. Operation
• 1.12. Clutch Assemblies
• 1.13. Description
• 1.14. Operation
• 1.15. Transmission Operation in Neutral
• 1.16. Input Shaft, Forward Shaft, and Clutch Assembly
• 1.17. Description
• 1.18. Operation
• 1.19. Reverse, Second-Speed, and First-Speed Shaft and Clutch Assembli
• 1.20. Description
• 1.21. Operation
• 1.22. Third-Speed Shaft, Gear, and Clutch Assembly
• 1.23. Description
• 1.24. Operation
• 1.25. Fourth-Speed Shaft and Clutch
• 1.26. Description
• 1.27. Operation
• 1.28. Output Shaft
• 1.29. Description
• 1.30. Operation
• 1.31. Hydraulic Description and Operation
• 1.32. Sump, Filter, and Pump
• 1.33. Transmission Charge Pump
• 1.34. Pressure Regulator Valve
• 1.35. Relief Valve
• 1.36. Transmission Control Valve
• 1.37. Solenoid Valves
• 1.38. Direction Spools
• 1.39. Range Spools
• 1.40. Modulator Valves
• 1.41. Table 1. Solenoid Controls
• 2. RM0635-(06-2007)-US-EN
• 2.1. Four-Speed Powershift Transmission
• 2.2. Safety Precautions Maintenance and Repair
• 2.3. General
• 2.4. Torque Converter Repair
• 2.5. Torque Converter, Remove
• 2.6. Torque Converter, Disassemble
• 2.7. Clean and Inspect
• 2.8. Torque Converter, Assemble
• 2.9. Torque Converter (Turbine) Housing, Disassemble
• 2.10. Relief Valve for Lube Pressure, Disassemble and Assemble
• 2.11. Oil Sealing Rings Sleeve, Replace
• 2.12. Torque Converter Housing, Assemble
• 2.13. Torque Converter, Install
• 2.14. Transmission Repair
• 2.15. Remove, Transmission Only
• 2.16. Transmission and Engine Assembly, Remove
• 2.17. Transmission, Disassemble
• 2.18. Output Shaft, Disassemble and Assemble
• 2.19. Fourth-Speed Shaft, Disassemble and Assemble
• 2.20. Third-Speed Shaft, Disassemble and Assemble
• 2.21. Forward Shaft and Clutch, Disassemble and Assemble
• 2.22. Reverse and Second-Speed Shaft and Clutch, Disassemble and Assem
• 2.23. First-Speed Shaft and Clutch, Disassemble and Assemble
• 2.24. Input Shaft, Disassemble and Assemble
• 2.25. Speed Sensor, Install
• 2.26. Transmission, Clean and Inspect
• 2.27. Transmission, Assemble
• 2.28. Control Valve
• 2.29. Clean and Inspect
• 2.30. Assemble and Install
• 2.31. Install, Transmission
• 2.32. Install, Transmission and Engine Assembly
• 2.33. Clean Oil System of Transmission After Major Repair
• 2.34. Automatic Powershift Control (APC 100)
• 2.35. Functional Description
• 2.36. Transmission Control Lever
• 2.37. First-Speed Shaft Bearings Adjustment
• 2.38. Torque Converter Stall Speed Check
• 2.39. Transmission Oil Pressures Check
• 2.40. Clutch Pressures Check
• 2.41. Torque Converter (Torque Converter Regulator) Oil Pressure Check
• 2.42. Troubleshooting
• 2.43. Transmission Controller (APC 100)
• 2.44. Table 1. Flange Nut Torque
• 2.45. Table 2. APC 100 Control Module (Pin Connections)
• 2.46. Table 3. Hobbs Gear Selector Connections
• 2.47. Table 4. Example Torque Values at Dimensions Shown
• 2.48. Table 5. Transmission Pressures
• 3. RM0046-(11-2014)-US-EN
• 4. RM0097-(05-2012)-US-EN
• 4.1. Hydraulic Gear Pumps
• 4.2. Safety Precautions Maintenance and Repair
• 4.3. Description
• 4.4. Operation
• 4.5. Flow Control Valve
• 4.6. Relief Valve
• 4.7. Hydraulic Gear Pump Repair
• 4.8. Disassemble
• 4.9. Inspect
• 4.10. Assemble
• 4.11. Install
• 4.12. Pump Output Check
• 4.13. Method No. 1
• 4.14. Method No. 2
• 4.15. Hydraulic System Air Check
• 4.16. Troubleshooting
• 5. RM0231-(01-2016)-US-EN
• 5.1. General
• 6. RM0723-(07-2014)-US-EN
• 7. RM1036-(01-2012)-US-EN
• 7.1. Brake Accumulator
• 7.2. Safety Precautions Maintenance and Repair
• 7.3. General
• 7.4. Description and Operation
• 7.5. Accumulator Maintenance
• 7.6. Pre-Charge Check
• 7.7. Pre-Charge Filling
• 7.8. Disassemble
• 7.9. Inspect
• 7.10. Assemble
• 7.11. Replace
• 7.12. Table 1. Accumulator Pressures
• 8. RM1038-(01-2012)-US-EN
• 8.1. Service Brake
• 8.2. Safety Precautions Maintenance and Repair
• 8.3. General
• 8.4. Description and Operation
• 8.5. A917, E117, and F117 Only
• 8.6. B222 Only
• 8.7. General
• 8.8. Drive Wheels and Tires
• 8.9. Brake Housing
• 8.10. Spindle and Brake Cover
• 8.11. Disassemble
• 8.12. Ground and Polished Parts
• 8.13. Parts With Rough Finish
• 8.14. Wet Disc Brake and Axle Assembly
• 8.15. Inspect
• 8.16. Face Seals
• 8.17. Replace
• 8.18. Assemble
• 8.19. Brake Housings
• 8.20. Install
• 8.21. Hub Oil Seals
• 8.22. Spindle and Brake Cover
• 8.23. Brake Housing
• 8.24. Drive Wheels and Tires
• 8.25. Pressure Switch
• 8.26. Replace
• 8.27. Accumulator
• 8.28. Brake Pedal Valves (Treadle Valves) Repair
• 8.29. All Models Except A917, B222, E117, and F117
• 8.30. Clean and Inspect
• 8.31. Install
• 8.32. A917, B222, E117, and F117
• 8.33. Clean and Inspect
• 8.34. Install
• 8.35. Brake System Air Removal
• 8.36. Specifications
• 8.37. Brake Coolant
• 8.38. Coolant Change Intervals
• 8.39. Hydraulic Fluid
• 8.40. Troubleshooting
• 8.41. Measurements and Adjustments
• 8.42. Table 1. Friction Disc
• 8.43. Table 2. Stationary Disc
• 8.44. Table 3. Wheel Hub and Brake Housing Torque Chart
• 8.45. Table 4. Brake Housing Cover Torque Chart
• 9. RM1102-(08-2004)-US-EN
• 9.1. Hydraulic System
• 9.2. Safety Precautions Maintenance and Repair
• 9.3. General
• 9.4. Description and Operation
• 9.5. Hydraulic Plate
• 9.6. Hydraulic Pumps
• 9.7. Cab Manifold
• 9.8. Oil Cooled Brakes (Service Brakes)
• 9.9. Lift/Tilt Functions
• 9.10. Over Lower Interrupt
• 9.11. Lift Interrupt
• 9.12. Heat Exchanger System
• 9.13. Steering Control System
• 9.14. Brake System
• 9.15. Hydraulic Pump Repair
• 9.16. Disassemble
• 9.17. Tandem Gear Pump
• 9.18. Tri-Section Gear Pump
• 9.19. Clean and Inspect
• 9.20. Assemble
• 9.21. Tandem Gear Pump
• 9.22. Tri-Section Gear Pump
• 9.23. Install
• 9.24. Pump Output Check
• 9.25. First Method
• 9.26. Second Method
• 9.27. Cab Manifold
• 9.28. Disassemble Valves and Pressure Switches
• 9.29. Clean and Inspect
• 9.30. Assemble Valves and Pressure Switches
• 9.31. Install
• 9.32. Lift and Lower Circuit
• 9.33. Description
• 9.34. Operation
• 9.35. Lift Circuit
• 9.36. Lowering
• 9.37. Lowering Control Valves
• 9.38. Repairs
• 9.39. General
• 9.40. Remote Control Valve
• 9.41. Lift Manifold
• 9.42. Checks and Adjustments
• 9.43. Tilt Control Circuit
• 9.44. Description
• 9.45. Operation
• 9.46. Tilt/Lift Spool
• 9.47. Relief Valves in Main Control Valve
• 9.48. Relief Valves, Tilt Lock
• 9.49. Repairs
• 9.50. General
• 9.51. Relief Valves, Tilt Lock, Disassemble
• 9.52. Clean and Inspect
• 9.53. Checks and Adjustments
• 9.54. Attachment Circuit Valves
• 9.55. General
• 9.56. Selector Valves Auxiliary Functions
• 9.57. Carriage Solenoid Valve
• 9.58. Repairs
• 9.59. Carriage Solenoid Valve
• 9.60. Checks and Adjustments
• 9.61. Other Hydraulic Components
• 9.62. Description and Operation
• 9.63. Relief Valves in Steering and Lift Circuits
• 9.64. Reducer Valve
• 9.65. Hydraulic Filters
• 9.66. Hydraulic Filters
• 9.67. Suction Filters
• 9.68. High Pressure Filter
• 9.69. Brake Filter
• 9.70. Return Line Filters
• 9.71. Hydraulic Hose Repair
• 9.72. Checks and Adjustments
• 9.73. Pilot Setting, Check
• 9.74. Return Pressure, Check
• 9.75. Main Function Relief Valve Pressure, Check
• 9.76. Hydraulic Tank Breathers
• 9.77. Specifications
• 9.78. Hydraulic Pumps Output at 2100 rpm (Governed Speed)
• 9.79. Cummins 290 Hp (216 kW) Engine
• 9.80. Cummins 330 Hp (246 kW) Engine
• 9.81. Relief Valves (Approximate Operating Pressures)
• 9.82. Check Port Pressures
• 9.83. Main Hydraulic Filters
• 9.84. Tank Capacity
• 9.85. Torque Specifications
• 9.86. Remote Control Valves
• 9.87. Attachment Control Valve
• 9.88. Carriage Solenoid Valve
• 9.89. Troubleshooting
• 9.90. Lift and Lower Circuit
• 9.91. Tilt Circuit
• 9.92. Attachment Circuit Valves
• 9.93. Attachment Control Valve
• 9.94. Carriage Solenoid Valve
• 9.95. Other Hydraulic Components
• 9.96. Accumulator Circuit
• 9.97. MPa ( 725 psi) Pilot Circuit
• 9.98. Park Brake Circuit
• 9.99. Table 1. Brake Treadle Settings
• 9.100. Table 2. Gauge Ranges
• 9.101. Table 3. Pressure Settings
• 10. RM1108-(08-2004)-US-EN
• 10.1. Hydraulic Plate
• 10.2. Safety Precautions Maintenance and Repair
• 10.3. General
• 10.4. Description and Operation
• 10.5. Hydraulic Oil Supply
• 10.6. Manifold, Section 1 of Hydraulic Plate
• 10.7. Main Control Valve, Section 2 of Hydraulic Plate
• 10.8. Description
• 10.9. Operation
• 10.10. Return Manifold, Section 3 of Hydraulic Plate
• 10.11. Brake Manifold, Section 4 of Hydraulic Plate
• 10.12. Cooling Circuit
• 10.13. Service Brake
• 10.14. Parking Brake
• 10.15. Flow Amplifier, Section 5 of Hydraulic Plate
• 10.16. Manifold, Section 1 of Hydraulic Plate
• 10.17. General
• 10.18. Valves and Pressure Switches
• 10.19. Main Control Valve, Section 2 of Hydraulic Plate
• 10.20. Disassemble
• 10.21. Auxiliary Section
• 10.22. Lift Section
• 10.23. Lift/Tilt Section
• 10.24. Clean and Inspect
• 10.25. Assemble
• 10.26. Auxiliary Section
• 10.27. Lift Section
• 10.28. Lift/Tilt Section
• 10.29. Install
• 10.30. Return Manifold, Section 3 of Hydraulic Plate
• 10.31. Disassemble
• 10.32. Clean and Inspect
• 10.33. Assemble
• 10.34. Install
• 10.35. Brake Manifold, Section 4 of Hydraulic Plate
• 10.36. Clean and Inspect
• 10.37. Install
• 10.38. Flow Amplifier, Section 5 of Hydraulic Plate
• 10.39. Hydraulic Hose Repair
• 10.40. Hydraulic Hose Identification
• 10.41. Torque Values
• 10.42. Measurements and Adjustments
• 10.43. Measurements
• 10.44. Adjustments
• 10.45. Troubleshooting
• 10.46. Table 1. Pilot Hoses
• 10.47. Table 2. Brake Hoses
• 10.48. Table 3. Auxiliary Hoses With Alternating P and T
• 10.49. Table 4. Steer Hoses
• 10.50. Table 5. Pressure Settings at 2100 RPM
• 11. RM1109-(07-2014)-US-EN
• 12. RM1110-(08-2004)-US-EN
• 12.1. Instrument Panel Indicators and Senders
• 12.2. Safety Precautions Maintenance and Repair
• 12.3. General
• 12.4. Description
• 12.5. General
• 12.6. Instrument Panel Meters, Indicators, and LCD Display
• 12.7. Error Code Display
• 12.8. Connector
• 12.9. Seat Switch Logic
• 12.10. Central Warning Light Output
• 12.11. Buzzer Output
• 12.12. Instrument Panel Component Replacement
• 12.13. Instrument Panel
• 12.14. Replace
• 12.15. Sender Replacement
• 12.16. Fuel Level Sender
• 12.17. Pressure Sender
• 12.18. Temperature Sender
• 12.19. Low Coolant Sender
• 12.20. Vacuum Switch
• 12.21. Crankshaft Position Sensor
• 12.22. Table 1. Instrument Panel and Indicators
• 12.23. Table 2. Switches Description
• 12.24. Table 3. Pin Description
• 12.25. Table 4. Sender Description
• 13. RM1114-(07-2014)-US-EN
• 14. RM1116-(11-2014)-US-EN
• 15. RM1117-(01-2012)-US-EN
• 15.1. Parking Brake
• 15.2. Safety Precautions Maintenance and Repair
• 15.3. General
• 15.4. Description and Operation
• 15.5. Parking Brake Valve Replacement
• 15.6. Clean and Inspect
• 15.7. Install
• 15.8. Parking Brake Caliper Repair
• 15.9. Disassemble
• 15.10. Inspect
• 15.11. Install
• 15.12. Bleed Brakes
• 15.13. Brake Pad Repair
• 15.14. Inspect
• 15.15. Install
• 15.16. Seals Repair
• 15.17. Install
• 15.18. Specifications
• 15.19. Torque Requirements
• 15.20. Wear Limits
• 15.21. Lining to Disc Clearance
• 15.22. Troubleshooting
• 15.23. Table 1. Brake Pad Adjustment
• 15.24. Table 2. Torque Requirements
• 15.25. Table 3. Wear Limits
• 15.26. Table 4. Lining to Disc Clearance
• 16. RM1118-(01-2011)-US-EN
• 16.1. Safety Precautions Maintenance and Repair
• 16.2. General
• 16.3. Description
• 16.4. Counterweight Repair
• 16.5. Main Counterweight (Cast)
• 16.6. Counterweight
• 16.7. Rear Counterweight (Cast)
• 16.8. Install
• 16.9. Main Counterweight (Fabricated)
• 16.10. Install
• 16.11. Install
• 16.12. Floor Plates, Handrails, and Steps
• 16.13. Hydraulic Tank Repair
• 16.14. Small Leaks
• 16.15. Large Leaks
• 16.16. Steam Method
• 16.17. Chemical Solution Method
• 16.18. Other Methods of Preparation for Repair
• 16.19. Install
• 16.20. Suction Screen and Inspection Cover